Help enabling 5 Axis on mach3 postprocessor

[Anonymous]

Hello, I am new to fusion 360 as well as Manufacturing.

What I need is:

*To modify the post processor to activate A and B axis (A is mounted in Z axis and B is mounted in Axis).

*Give the limits of A and B {(A will be -180,180)(B needs to be -120,120 )[I use 0 as center]}

*To make sure the Machinning limits don't exceed the soft limits of my machine.

*That the mach3 software tool path shows the right path.

What I'v been doing so far:

I have a no brand CNC 5Axis Machine. I've been using mach 3 post processor with 3 axis (XYZ) and works just fantastic, The problem is when I try to run the 2 extra axis (A and B-head to head-).

I have been doing research and learning about rewriting the post processor, I have also been reading all over the place and I could not figure out how to do it right. So far I can make it move the 5 axis at the same time but does not follow the specific path. In mach3 software it shows the right path but when I execute the program on my CNC machine it does not respond correctly. I am running out of ideas of how to modify the program so some assistance will be really appreciated.

I have been following step by step the forums but no luck so far with modifying the post processor.

The main post processor for my CNC

for the 3axis, I use "mach3mill" (Which I try to modify with no success).

The one I found (in fusion360 forums)for the 5axis is "mach3mill X axis A and B" but this does not work right (I been trying to modify with no success).

The most resent I've been trying is the "Current progress 5axismaker1" I did modification on my program mach3 software (Using A as C axis).

Thank you in advance!

[boopathi.sivakumar]

@Anonymous 

i just want to make sure that your machine kinematics is something like this.

If so then change the onopen section like the below one

function onOpen() {

  if (true) {
  var bAxis = createAxis({coordinate:1, table:true, axis:[1, 0, 0], range:[-120 - 0.0001, 120 + 0.0001], preference:0});
  var aAxis = createAxis({coordinate:0, table:true, axis:[0, 0, 1], range:[-180 - 0.0001, 180 + 0.0001], preference:0});
  machineConfiguration = new MachineConfiguration(bAxis,aAxis);

    setMachineConfiguration(machineConfiguration);
    optimizeMachineAngles2(0); // map tip mode
  }

If your machine has TCP enabled then above code will work fine,If it is not the change  optimizeMachineAngles2(0);

to  optimizeMachineAngles2(1);

This should work fine,

Change and test it carefully.

Still have problems attach your .f3d file and the issue your are facing probably video will give us the better understanding.

[Anonymous]

Hello boopathi,

Thank you so much for your quick respond, it give me gratification that Autodesk cares about the costumers, giving me peace of mind that I choose the right software company 😊

After activating the 5 axis on the “mach3mill.cps” (which I will upload as mach3mill5axis.txt) the machine fallows its own path. The limits on B axis are out of reach. I try the “optimizeMachineAngles2(0 and 1)” with no success.

I am doing a really simple pass using the multi-axis flow, which I am attaching.

I also I am attaching the screenshot of the limits going beyond what is desire.

When I execute the program in my CNC machine in the second attempt (changing optimizeMachineAngles2)  I didn’t zero assuming it will do automatic which it didn’t  do it beguiling to move the A and B axis.

Thank you.

[Anonymous]

hello boopathi

I try to send the video but it does not let me, or i don't not how to uploaded. here are pictures

[daniel_lyall]

Set this bit to false on both axis, table true means the a, b or c are on the machine table, not head.

table:true

[boopathi.sivakumar]

Yep @daniel_lyall was right I just missed this one.change it like this and try to run.

function onOpen() {

  if (true) {
  var bAxis = createAxis({coordinate:1, table:false, axis:[1, 0, 0], range:[-120 - 0.0001, 120 + 0.0001], preference:0});
  var aAxis = createAxis({coordinate:0, table:false, axis:[0, 0, 1], range:[-180 - 0.0001, 180 + 0.0001], preference:0});
  machineConfiguration = new MachineConfiguration(bAxis,aAxis);

    setMachineConfiguration(machineConfiguration);
    optimizeMachineAngles2(0); // map tip mode
  }

If it not works then 

Make sure to zip the file before attaching and send the model file (.F3d) also
File>Export>.F3d.
Take the video of how the machine is moving and attach it here.
Zip all file.

[Anonymous]

Hello daniel_lyal,

Thank you for the assistance. I fallow your advice changing the values on table to false, now it does not give me a tool path. When fusion processes the file, the safe error shows:

Error: Rewind of machine is required for simultaneous multi-axis toolpath.

Error in operation: 'Flow1'

Failed while processing onLinear5D() for record 663.

I am using mach3mill cps file to post process.

Thank you.

[Anonymous]

Hello boopathi.sivakumar,

after make the new changes, it shows the error:

###############################################################################

Error: Rewind of machine is required for simultaneous multi-axis toolpath.

Error in operation: 'Flow1'

Failed while processing onLinear5D() for record 663.

###############################################################################

Error: Failed to invoke function 'onRewindMachine'.

Error: Failed to invoke 'onRewindMachine' in the post configuration.

Error: Failed to execute configuration.

Stop time: Monday, November 25, 2019 3:17:21 AM

Post processing failed.

I am trying to attach the file but the forum don't want to upload the video.

I reduce the quality of the video about 30 MB and still dont want to take it.

I compress it as .7z and still dont want to take the file.

if i figure it out I will update the video

Thank you.

[Anonymous]

Hello @boopathi.sivakumar,

I did my reserch an here is the video with the files.

IF does not work the screen cast window ...

https://autode.sk/35ryUI4

[boopathi.sivakumar]

@Anonymous 

Change the code like this add cyclic:true

if (true) {
    var bAxis = createAxis({coordinate:0, table:false, axis:[1, 0, 0], range:[-120 - 0.0001, 120 + 0.0001], preference:0});
    var aAxis = createAxis({coordinate:1, table:false, axis:[0, 0, 1], cyclic:true,range:[0, 360], preference:0});

Now it will post the code if your machine supports 0-360 then leave as like the above ,If it supports -180 to 180 then use the below code

if (true) {
    var bAxis = createAxis({coordinate:0, table:false, axis:[1, 0, 0], range:[-120 - 0.0001, 120 + 0.0001], preference:0});
    var aAxis = createAxis({coordinate:1, table:false, axis:[0, 0, 1], cyclic:true,range:[-180, 180], preference:0});
    machineConfiguration = new MachineConfiguration(bAxis,aAxis);

try with this code and one more thing maybe the direction in the machine will be opposite of what you are trying to program in the software in that case in the axis use -1 like this axis:[-1,0,0] in the var bAxis.

try this and give me the feedback

[Anonymous]

hello @boopathi.sivakumar'

Thank you for your fast respond.

The code that you give activates the 5 axis, and generate the code!

if (true) {
    var bAxis = createAxis({coordinate:0, table:false, axis:[1, 0, 0], range:[-120 - 0.0001, 120 + 0.0001], preference:0});
    var aAxis = createAxis({coordinate:1, table:false, axis:[0, 0, 1], cyclic:true,range:[-180, 180], preference:0});
    machineConfiguration = new MachineConfiguration(bAxis,aAxis); 

However, the soft limit of b was way to off. I invert the "a and b" coordinate and now it respect the soft limits given.

when i try to program a simpler program so i can adjust the point, the A axis wont move wile the b axis do the job.
i try to change setting like changing values on axis and optimizeMachineAngles2 values with no success.
I believe that in order to work proper the A axis need to move either -90 or 90 (from 0 that is the center programed).

I will attach the new program, video and post processor program.

https://autode.sk/2KSdn3A

[boopathi.sivakumar]

I think we need some fine tuning,we are very much close, I'm out of office now do one thing Just create a manual program that rotates along
A45 B0 ,
A45 B90,
A45 B -90 and
A45 B-180/180

Take toolpath individually first on any one direction.and then multiple sides.

Record the video of manual nc program and send me the manual codes which is working fine and the setup you have made in the machine while running this manual code
I'll have a look at it and then we will take it forward.

[Anonymous]

Hello @boopathi.sivakumar 

Thank you for you quick response!

I just saw the message and I have to learn how to do manually numeric code. I try to do calculation as you  suggest but I could not figure it out.

I am attaching the video, and file that I did the manual numeric code as well as my mach3 configuration, and in the two pictures.

Once again thank you so much for the help. It does make a huge differences for the software experiences (fusion 360).

https://autode.sk/2skd23r

[boopathi.sivakumar · Accepted solution]

@Anonymous 

Thanks for the feedback do the modification like this 

if (true) {
    var bAxis = createAxis({coordinate:1, table:false, axis:[1, 0, 0], range:[-120 - 0.0001, 120 + 0.0001], preference:0});
    var aAxis = createAxis({coordinate:0, table:false, axis:[0, 0, 1], cyclic:true,range:[-180,180], preference:0});
    machineConfiguration = new MachineConfiguration(bAxis,aAxis);

Now it will work. and i have attached a sample program also please test it and it should match with simulation i have attached here

Screencast Video 

[engineguy]

@boopathi.sivakumar 

@cuan_cuan 

@daniel_lyall 

Really, really nice work guys, you are a credit to the Community. A very good exercise in modifying a Post Processor.

I understand that as an excercise in coding it is very interesting but aside from that why not just use a PP that already does 5 Axis that only needs very minor tweaks saving loads of work.

Here is a screen cast of a flow strategy (Don`t know why I it wouldn`t go all the way round when doing multiple passes) and the code, it is already setup as it should be according to your machine build, the axis around the Z is a C axis and the tilting head is an A axis, seems to work fine and looks to be outputting code correctly.

To get to where you are in that it is very close to what I have here is a real achievement for sure 🙂🙂

Anyway, it is just for interest so have a look and critique it as much as you like 🙂🙂

Code file attached.

Regards

Rob

 

[Anonymous]

Hello @boopathi.sivakumar 

The program activate the 5 axis and respect the limits! This is so awesome!!!!

Once again, thank you for the fast response.

The nc program "Trail_5 one pass" which I am uploading show:

* A axis is off in the path for example line 14 an 16 i think should be A0 (which I modify). Then i realized that the next modification needs to be into the x axis as well (because the x axis needs to back up or forward so A and B axis hit the target) so I assume that that is in fusion 360.

* Also I notices that does not raise the tip (drill bit/I dont know how to call it), I think this may cut unintentionally material (which I am assuming because I am cutting air).

https://autode.sk/35y83KH

Once again thank you!

[Anonymous]

Hello @engineguy 

Thank you for your suggestions. I really appreciated the good vibes and good intention for help.

I try for almost one Mont (about 10 hours a day/each day) to configure it post possessors that have 5 axis activate. I have no ninja skills on languages or even on CNC. My experiences in the CAM/CAD world is about 3 months old. with this been said, I try and actually i could activate the 5 axis but i have to deactivate bunch of stuff in the pp that was scary and not reliable. Also one of my huge helpers to understand was the autodesk forum, you tube and in overall research.

In overall I believe that I was just need little be of custom modification because I think my CNC is not that common or if is, it seems that people with ninja skills have it and they know it all! like @boopathi.sivakumar that is helping me tremendous.

I try your code that you post, but is the problem that I have in the beguine about the limits on the A and B Axis.

Any how thank you for your suggestions!

[boopathi.sivakumar]

could you please test and send me the video of the attached code

[Anonymous]

Hello @boopathi.sivakumar 

I am sending the video. What can I do to help out and speed the process?

I am attaching pictures of how it does look in mach3 software.

https://autode.sk/2QRm2XJ

[daniel_lyall]

@Anonymous You could post the mach3 config file for your machine all one needs is a copy off mach3 then you can test different things easily of line.